Pre-Cut Synthetic Turf Grids

ABSTRACT

My invention modifies synthetic turf in its traditional solid roll turf form for distribution and sale by adding a manual or machine design cutting process to change the overall look and shape of the finished turf material offering a new and improved method of design and application allowing seamless integration and use with other materials for hardscape installations.

CROSS-REFERENCE TO RELATED APPLICATIONS

Design Patent Application no. 29686328

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

n/a

REFERENCE TO SEQUENCE LISTING

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BACKGROUND OF INVENTION

My invention consists of a new pre-cut synthetic turf grid design applique process used in the manufacturing of synthetic turf. This new finishing process allows for easier installation and integration with other materials for synthetic turf walkways, patios, pool surrounds, driveways, walls, & fences, considered ‘hardscapes’, for the synthetic turf industry, building & landscape design industry, & DIY industry.

It is a growing trend to have grass or synthetic turf installed in-between and around other surface materials to make synthetic turf and paver, stone, brick, tile, & wood grid patterns for different hardscapes (see Drawings page 1, FIG. 1 & Drawings page 2, FIG. 7). The most common way to accomplish this feature is to start with smaller pieces of solid turf cut from larger rolls. Then, many long and short strips are manually cut to size ‘in-the-field’ and connected, seamed and all joints are glued in place in-between and around each paver stone, brick, tile, or wood design (square, circle, rectangle, diagonal) making intricate patterns and connections individually one at a time.

It takes a very experienced synthetic turf contractor and is very time consuming and expensive. Currently, synthetic turf is not manufactured or distributed in pre-sized and pre-cut synthetic turf grids. Standard synthetic turf is only available in solid rolls between 12′ to 15′ wide and usually sold by the length or total square foot in solid pieces (length & width), solid modular strips (DN/20090208674), or solid square tiles (DN/20140286704).

BRIEF SUMMARY OF INVENTION

The claimed pre-cut synthetic turf grids are pre-sized and patterned artificial turf/grass grids with the material shapes already cut out and removed creating turf spaces or voids allowing for quicker and easier installation either before or after the paver, stone, brick, tile, or wood materials are in place to make beautiful square, circle, rectangular and diagonal patterned turf grid designed hardscapes. This makes installation possible without needing an expensive specialty turf contractor.

Pre-cut synthetic turf grids make complex designs & installation much easier than traditional synthetic turf & installation methods by eliminating all the cutting, seaming, gluing, special tools and training. Pre-cut synthetic turf grids improve installation quality by reducing all the traditional weak points and can shorten labor time from days to hours. Pre-cut synthetic turf grids will allow for a virtually seamless install with no intricate fitting or wasted material due to errant cuts or mistakes made ‘in the field’.

Pre-cut synthetic turf grids will be available in a variety of sizes and configurations to be used with the most common size shapes (square, circle, rectangle) of pavers, stones, bricks, tiles, and wood tiles available at home improvement stores. Pre-cut synthetic turf grids can be connected to other pre-cut synthetic turf grid pieces to formulate any total grid size area desired. They are easy to connect using only seaming tape to make many different desired shapes.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a Top Plan View of pre-cut synthetic turf grid square pattern. The 9 white squares represent the cut-out square turf spaces or voids with no turf and where the other material (paver, stone, brick, tile, or wood tile) would be placed. All the boarder lines represent the grid boarder design and the shaded horizontal line pattern represents what would be the synthetic turf fibers that would replicate the look of grass.

FIG. 2 is a Bottom Plan View which is comprised of a polypropylene backing that the turf fibers are tufted into forming many rows.

FIG. 3 is a Left Side Elevation View, Right Side Elevation View, Top Side Elevation View, & Bottom Side Elevation View, which are all identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

FIG. 4 is a Top Plan View which is same as FIG. 1 except this example does not have the turf grid boarder around the perimeter.

FIG. 5 is a Bottom Plan View, same as FIG. 2 except this example does not have the turf grid boarder around the perimeter.

FIG. 6 is a Left Side Elevation View, Right Side Elevation View, Top Side Elevation View, & Bottom Side Elevation View, which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

FIG. 7 is a Top Plan View of pre-cut synthetic turf grid diagonal pattern with boarder. The white diagonal squares represent the cut-out turf spaces or voids with no turf and where the other material (paver, stone, brick, tile, or wood tile) would be placed. All the boarder lines represent the grid boarder design and the shaded horizontal line pattern represents what would be the synthetic turf fibers that would replicate the look of grass.

FIG. 8 is a Bottom Plan View of the diagonal pattern with boarder which is comprised of a polypropylene backing that the turf fibers are tufted into forming many rows.

FIG. 9 is a Top Side Elevation View & Bottom Side Elevation View which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

FIG. 10 is a Left Side Elevation View & Right Side Elevation View which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

FIG. 11 is a Top Plan View of pre-cut synthetic turf grid circle pattern. The white circles represent the cut-out turf spaces or voids with no turf and where the other material (paver, stone, brick, tile, or wood tile) would be placed. All the boarder lines represent the grid boarder design and the shaded horizontal line pattern represents what would be the synthetic turf fibers that would replicate the look of grass.

FIG. 12 is a Bottom Plan View which is comprised of a polypropylene backing that the turf fibers are tufted into forming many rows.

FIG. 13 is a Top Side Elevation View, & Bottom Side Elevation View, which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

FIG. 14 is a Left Side Elevation View & Right Side Elevation View which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

FIG. 15 is a Top Plan View of pre-cut synthetic turf freeform grid circle pattern. The white circles represent the cut-out turf spaces or voids with no turf and where the other material (paver, stone, brick, tile, or wood tile) would be placed. All the boarder lines represent the grid boarder design and the shaded horizontal line pattern represents what would be the synthetic turf fibers that would replicate the look of grass.

FIG. 16 is a Bottom Plan View which is comprised of a polypropylene backing that the turf fibers are tufted into forming many rows.

FIG. 17 is Top Side Elevation View, & Bottom Side Elevation View, which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

FIG. 18 is a Left Side Elevation View & Right Side Elevation View which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

DETAILED DESCRIPTION OF THE INVENTION

Pre-cut synthetic turf grids are used in architectural and landscape designs for hardscapes most commonly used to make grass and paver, stone, brick, tile, or wood patterned walkways, patios, driveways, walls and fence installations.

Traditional synthetic turf is currently only manufactured and distributed in solid rolls between 12′ to 15′ wide and usually sold by the length or total square foot. It is typically sold and installed by specialty turf contractors and there are usually large minimums of square footage required for a professional installation job. Any special designs or patterns including walkway grids with lots of additional cutting and seaming labor is an additional premium charge and only attempted by highly experienced experts.

Pre-cut synthetic turf grids eliminate all the complicated cutting, fitting, seaming, & gluing of traditional synthetic turf designs by manufacturing and distributing an already pre-sized, patterned, & factory pre-cut by hand or machine synthetic turf grid product (See Drawings FIGS. 1,4 & 7).

Pre-cut synthetic turf grids are made using a standard piece of synthetic turf finished goods. Pre-cut pieces of synthetic turf grids can be manufactured from a traditional 12′ or 15′ wide standard size roll, either in place on the roll or by cutting smaller sections from the standard roll. When cutting by hand, either on the roll, or a smaller piece section, the desired working length or piece size of the turf material is rolled out onto floor or work table with the underside, usually comprised of a polypropylene backing, facing up. Next, the square, circle, rectangle or diagonal shape grid pattern design template made from wood, plastic or metal and sized accordingly per a standard specification is applied to the turf backing or underside (See Drawings FIGS. 2,5 & 8 for finished product underside). Then each pattern shape is manually cut out and removed by hand following the template with a carpet cutting tool creating a pattern of turf spaces or voids.

If using a CNC machine, the standard roll of turf or section of turf piece size is loaded into the CNC machine and the specific design template CAD file would be initiated and used to drive the CNC machine and the grid pattern would be cut automatically (CNC knives or laser cutting machine). When pre-cut by machine using a CAD file, the final design can be more intricate and easily modified per specification or need (See Drawings FIG. 1 showing design with boarder & FIG. 4 showing design without boarder). The excess synthetic turf pieces are removed by hand or machine creating a pattern of turf spaces or voids, then turf is folded or rolled by hand or machine and packaged accordingly for distribution or sale.

The pre-cut synthetic turf grids allow a DIYer or any type of contractor to install for example; a beautifully designed & complex walkway by simply rolling out or unfolding the pre-cut synthetic turf grid on top of an already properly prepared sub-base and finished by installing the corresponding sized paver, stone, brick, tile, or wood pieces in the already cut out turf spaces or voids to form the finished product. Depending on the desired finished aesthetic and application, the final turf height (See Drawings FIG. 3) may need to be adjusted, secured and infill added by standard synthetic turf installation methods not being claimed. 

1) A synthetic turf system configured for placement atop a supporting sub-base, said synthetic turf system configured to simulate an elongate walkway, and comprising: A) an elongate turf layer configured to be manipulated into an uninstalled form such as by rolling or folding and also configured to be manipulated into an installed form such as by unrolling or unfolding when in said placement atop said supporting surface, said elongate turf layer itself comprising: 1) an elongate substantially planar backing layer having an upper side and a lower side, said lower side configured for placement atop said supporting sub-base; and 2) a plurality of elongate turf fibers, wherein each of said elongate turf fibers has one end attached proximate said elongate substantially planar backing layer, and each fiber also has a free end extending from said upper side of said elongate substantially planar backing layer, such that said elongate turf fibers extend in a generally coparallel manner such that they and said elongate substantially planar backing layer combine to simulate said elongate turf layer, wherein said elongate turf layer defines a plurality of cut-out voids extending completely through said elongate turf layer, B) a plurality of elements each configured to be placed into a corresponding one of said plurality of cut-out voids and atop said supporting sub-base, such that said turf layer combines with said plurality of elements to provide a finished product simulating an elongate walkway. 2) The synthetic turf system as claimed in claim 1, wherein said elongate turf layer in subsection “A” is configured to be manipulated into an uninstalled form by rolling and also configured to be manipulated into an installed form such as by unrolling. 3) The synthetic turf system as claimed in claim 2, wherein said cut-out voids are arranged in a recognizable repeating pattern. 4) The synthetic turf system as claimed in claim 1, wherein said cut-out voids are arranged in a recognizable repeating pattern. 5) The synthetic turf system as claimed in claim 1, wherein said elongate turf layer in subsection “A” replicates the look of grass. 6) The synthetic turf system as claimed in claim 1, wherein said elongate turf layer in subsection “A” is tufted polypropylene. 7) The synthetic turf system as claimed in claim 1, wherein said plurality of elements in subsection “B” are pavers, stones, bricks, tiles, or wood members.
 8. A method of manufacturing a synthetic turf system configured for placement atop a supporting sub-base, said method comprising A) providing an elongate turf layer configured to be manipulated into an uninstalled form such as by rolling or folding and also configured to be manipulated into an installed form such as by unrolling or unfolding when in said placement atop said supporting surface, said elongate turf layer itself comprising: 1) an elongate substantially planar backing layer having an upper side and a lower side, said lower side configured for placement atop said supporting sub-base; and 2) a plurality of elongate turf fibers, wherein each of said elongate turf fibers has one end attached proximate said elongate substantially planar backing layer, and each fiber also has a free end extending from said upper side of said elongate substantially planar backing layer, such that said elongate turf fibers extend in a generally coparallel manner such that they and said elongate substantially planar backing layer combine to simulate said elongate turf layer, wherein said elongate turf layer defines a plurality of cut-out voids extending completely through said elongate turf layer, B) providing a plurality of elements each configured to be placed into a corresponding one of said plurality of cut-out voids and atop said supporting sub-base, such that said turf layer combines with said plurality of elements to provide a finished product simulating an elongate walkway. 9) The method of manufacturing a synthetic turf system as claimed in claim 9, wherein said elongate turf layer provided in subsection “A” is configured to be manipulated into an uninstalled form by rolling and also configured to be manipulated into an installed form such as by unrolling. 10) The method of manufacturing a synthetic turf system as claimed in claim 9, wherein said cut-out voids are provided to be arranged in a recognizable repeating pattern. 11) The method of manufacturing a synthetic turf system as claimed in claim 8, wherein said cut-out voids are provided to be arranged in a recognizable repeating pattern. 12) The method of manufacturing a synthetic turf system as claimed in claim 8, wherein said elongate turf layer provided in subsection “A” replicates the look of grass. 13) The method of manufacturing a synthetic turf system as claimed in claim 8, wherein said elongate turf layer provided in subsection “A” is tufted polypropylene. 14) The method of manufacturing a synthetic turf system as claimed in claim 8, wherein said plurality of elements provided in subsection “B” are pavers, stones, bricks, tiles, or wood members.
 15. A method of installing a synthetic turf system atop a supporting sub-base, said method comprising A) providing an elongate turf layer configured to be manipulated into an uninstalled form such as by rolling or folding and also configured to be manipulated into an installed form such as by unrolling or unfolding when in said placement atop said supporting surface, said elongate turf layer itself comprising: 1) an elongate substantially planar backing layer having an upper side and a lower side, said lower side configured for placement atop said supporting sub-base; and 2) a plurality of elongate turf fibers, wherein each of said elongate turf fibers has one end attached proximate said elongate substantially planar backing layer, and each fiber also has a free end extending from said upper side of said elongate substantially planar backing layer, such that said elongate turf fibers extend in a generally coparallel manner such that they and said elongate substantially planar backing layer combine to simulate said elongate turf layer, wherein said elongate turf layer defines a plurality of cut-out voids extending completely through said elongate turf layer, B) providing a plurality of elements each configured to be placed into a corresponding one of said plurality of cut-out voids and atop said supporting sub-base, such that said turf layer combines with said plurality of elements; C) manipulating said elongate turf layer into an installed form such as by unrolling or unfolding said turf layer such that it is laid in a single thickness atop said supporting sub-base; and D) placing each of said plurality of elements into a corresponding one of said plurality of cut-out voids and atop said supporting sub-base, to provide a finished product simulating an elongate walkway. 16) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said elongate turf layer provided in subsection “A” is configured to be manipulated into an uninstalled form by rolling and also configured to be manipulated into an installed form such as by unrolling. 17) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said cut-out voids are provided to be arranged in a recognizable repeating pattern. 18) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said elongate turf layer provided in subsection “A” replicates the look of grass. 19) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said elongate turf layer provided in subsection “A” is tufted polypropylene. 20) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said plurality of elements provided in subsection “B” are pavers, stones, bricks, tiles, or wood members. 